Program Name or Ancillary Text eere.energy.gov
OfficeofEnergyEfficiency&RenewableEnergyAdvancedManufacturingOffice
QuadrennialTechnologyReview(QTR):TechnologyAssessment-SustainableManufacturing/[email protected]
SustainableManufacturingWorkshopPortland,ORJanuary6,2016
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QuadrennialTechnologyReview-2015hOp://www.energy.gov/quadrennial-technology-review-2015
TheQTRisacomprehensiveassessmentofscienceandenergytechnologyR&DopportuniHestoaddressournaHon'senergy-linkedeconomic,environmental,andsecuritychallenges.
• TheClimateAcHonPlan(June2013):– CutcarbonemissionsintheUnitedStates– PreparetheUnitedStatesfortheimpactsofclimatechange– LeadinternaYonaleffortstoaddressglobalclimatechange
• QuadrennialEnergyReview(QER):Analyzegovernment-wideenergy
policy,parYcularlyfocusedonenergyinfrastructure.
• QuadrennialTechnologyReview(QTR):AnalysisofthemostpromisingR&DopportuniYesacrossenergytechnologiesleadingtowardsacleanenergyeconomy.
TheresulHnganalysisandrecommendaHonsoftheQTR2015willinformthenaHonalenergyenterpriseandwillguidetheDepartmentofEnergy’sprogramsandcapabiliHes,budgetaryprioriHes,industryinteracHons,andnaHonallaboratoryacHviHes.
AdministraHonprioriHes
ExpandedScopeofQTR2015
TheQTRevaluatesmajorchangessincethefirstvolumeoftheQTRwaspublishedin2011andprovidesforwardleaninganalysistoinformDOE’sstrategicplanninganddecisionmaking,via:
• SystemsAnalyses–toevaluatethepower,buildings,industry,andtransportaYonsectors,enablingasetofopYonsgoingforward.
• TechnologyAssessments–Examinesindetail,thetechnicalpotenYalandenablingscienceofkeytechnologiesoutto2030.
• RoadMaps–UsestheseanalysesandassessmentstoextendR&DRoadmapsandframetheR&Dpathforward.
QTR2015
hOp://energy.gov/quadrennial-technology-review-2015
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SustainableManufacturingTechnologyAssessmentApproach–OutlineaframeworktobeOercaptureeconomy-wideaffectenergyandGHGemissions,andtohelpcharacterizeimprovementopportuniYes,including:• Changesinmaterialsandindustrial/manufacturingprocesses• Materialflowsandmanufacturedproducts• Cross-sectoralandlifecycleimpacts• EmbodiedEnergy&GHGs
• EnergyreducYons• EmissionsreducYons
• Useandre-useenergy/emissionsreducYons• Increasedvalue-added• Improvedquality/Improvedservice
Materials Manufacture Transport DisposalEndUse/Re-use
IntermediateUse
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SustainableManufacturingTechnologyAssessmentApproach–OutlineaframeworktobeOercaptureeconomy-wideaffectenergyandGHGemissions,andtohelpcharacterizeimprovementopportuniYes,including:• Changesinmaterialsandindustrial/manufacturingprocesses• Materialflowsandmanufacturedproducts• Cross-sectoralandlifecycleimpacts• EmbodiedEnergy&GHGs
• EnergyreducYons• EmissionsreducYons
• Useandre-useenergy/emissionsreducYons• Increasedvalue-added• Improvedquality/Improvedservice
Materials Manufacture Transport DisposalEndUse/Re-use
IntermediateUse
TargetTechnologies
• TransformaHve:Resultsinsignificantchangeinthelife-cycle
impact(energeYcoreconomic)ofmanufacturedproducts
• Pervasive:CreatesvalueinmulYplesupplychains,diversifiestheenduse/markets,appliestomanyindustrial/usedomainsinbothexisYngandnewproductsandmarkets
• GloballyCompeHHve:RepresentsacompeYYve/strategiccapabilityfortheUnitedStates
• SignificantinCleanEnergyIndustry:HasaquanYfiableenergeYc,environmentaloreconomicvalue.
TargetedtechnologiesareimpacWul,forexample:
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U.S.Economy:95Quads
U.S.Economy-WideEnergyDemand
Source:EIAMonthlyEnergyReview,Aug2014;AEO2014
2012Data
IndustryandManufacturingEnergyUse
U.S.Economy:95QuadsIndustry:31Quads
Source:EIAMonthlyEnergyReview,Aug2014;AEO2014
Fuelmixshowsdiversenatureofindustry
energyuse
2012Data *Renewablesconsistprimarilyofbiomassenergy(2.2Quads),withtheremainderfromonsitehydroelectric,geothermal,windandsolarenergy. 10
IndustryandManufacturingEnergyUse
Source:EIAMonthlyEnergyReview,Aug2014;AEO2014
2012Data
U.S.Economy:95Quads
2012Data *Renewablesconsistprimarilyofbiomassenergy(2.238Quads),withtheremainderfromonsitehydroelectric,geothermal,windandsolarenergy.
Manufacturing:24.4Quads
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Source:EIAMonthlyEnergyReview,Aug2014;AEO2014
Minusfeedstocks=19.2Quads
2012Data *Renewablesconsistprimarilyofbiomassenergy(2.238Quads),withtheremainderfromonsitehydroelectric,geothermal,windandsolarenergy.
U.S.Economy:95Quads
Manufacturing:24.4Quads
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Source:EIAMonthlyEnergyReview,Aug2014;AEO2014
Minusfeedstocks=19.2Quads
2012Data
Manufacturing:24.4Quads
*Renewablesconsistprimarilyofbiomassenergy(2.238Quads),withtheremainderfromonsitehydroelectric,geothermal,windandsolarenergy.
U.S.Economy:95Quads
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Source:EIAMonthlyEnergyReview,Aug2014;AEO2014
Minusfeedstocks=19.2Quads
2012Data
Manufacturing:24.4Quads
*Renewablesconsistprimarilyofbiomassenergy(2.238Quads),withtheremainderfromonsitehydroelectric,geothermal,windandsolarenergy.
U.S.Economy:95Quads
Ofthe24.4Quadsof
manufacturingenergy
demandà6.9Quadsareapplied.
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Systemsapproachtoindustrial&manufacturinganalysis
SystemBounds:ImpactedbyManufacturing
Note:1quad=1,000TBtu
U.S.EnergyEconomy95quads*
TransportaHonSector
27quads
ResidenHalSector
20quads
CommercialSector
17quads
IndustrialSector31quads
Supply-ChainSystems
ProducHon/FacilitySystems
ManufacturingSystems/UnitOperaHons
IndustrialSystems31quads
Equipmentusedformanufacturingprocessandnonprocessunitopera3ons
Networkoffacili3esandopera3onsinvolvedinmovingmaterialsthroughindustry,fromextrac3onofrawmaterialstotheproduc3onoffinishedgoods.
Equipment,processflow,andenergystrategiesthatcompriseagoods-producingfacility
• Technologiesforclean&efficientmanufacturing• Technologiestoimproveenergyuseintransporta3on• Technologiestoimproveenergyuseinbuildings• Technologiestoimproveenergyproduc3onanddelivery
EnergyProducHon
EnergyDelivery
Manufacturing,facility,andsupply-chainimprovementsreducethe12quadslostwithintheindustrialsector
Energy-efficienttechnologiesreducethe58quadslostthroughoutthe
U.S.EnergyEconomy
PetroleumRefinery
FacilitySteam
~26TBtu
~5TBtu
RefiningIndustry~4quads
Example:PetroleumRefining
AtmosphericDisHllaHonUnit
Hydro-cracker
CatalyHcReformer
~4TBtu ~2TBtu ~3TBtu
16*2012,EIA
DriverstoReduceEnergy&EmissionsthroughtheProductLifeCycle
EnergyIntensitye.g.:ProcessefficiencyProcessintegraYonWasteheatrecovery
CarbonIntensity,e.g.:Processefficiency
FeedstocksubsYtuYonGreenchemistry
Biomass-basedfuelsRenewables
UseIntensitye.g.:
RecyclingReuseandremanufacturing
MaterialefficiencyandsubsYtuYonBy-products
Product-Service-Systems17
EnergyIntensityImprovements
EnergyIntensitye.g.:ProcessefficiencyProcessintegraYonWasteheatrecovery
CarbonIntensity,e.g.:Processefficiency
FeedstocksubsYtuYonGreenchemistry
Biomass-basedfuelsProcesschangesRenewables
UseIntensitye.g.:
RecyclingReuseandremanufacturingMaterialefficiencyand
subsYtuYonBy-products
Product-Service-Systems
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TechnicalEnergySavingsOpportuniHes:
Source:DOE/AMO,EnergyBandwidthStudies(2015)Note:1quad=1000TBtu
CarbonIntensityImprovements
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Directemissionswithefficiencyimprovementsonly…
…andwithfuelswitchingandmaterialsubsYtuYon
ExampleanalysisusingtheBuildings,Industry,Transport,ElectricityScenario(BITES)tool
CarboncaptureandsequestraYon(CCS)technologiesofferaddiYonalopportuniYes
Agriculture,mining,construcYon:OpportuniYesforadvancedengines,biofuels,etc.
EnergyIntensitye.g.:ProcessefficiencyProcessintegraYonWasteheatrecovery
CarbonIntensity,e.g.:Processefficiency
FeedstocksubsYtuYonGreenchemistry
Biomass-basedfuelsProcesschangesRenewables
UseIntensitye.g.:
RecyclingReuseandremanufacturingMaterialefficiencyand
subsYtuYonBy-products
Product-Service-Systems
UseIntensityImprovements
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ExpandedTechnologyOpportunitySpace:• MaterialsShin–Toenableincreaseofsecondaryaluminumbymanufacturing• End-of-lifeshin–Toenablegreatercaptureanduseoflandfill+scrapexport• Systems-wide–Materials&productdesign,manufacturing,useandre-use.
EnergyIntensitye.g.:ProcessefficiencyProcessintegraYonWasteheatrecovery
CarbonIntensity,e.g.:Processefficiency
FeedstocksubsYtuYonGreenchemistry
Biomass-basedfuelsProcesschangesRenewables
UseIntensitye.g.:
RecyclingReuseandremanufacturingMaterialefficiencyand
subsYtuYonBy-products
Product-Service-Systems
SystemsapproachintheQTRIndustry&Manufacturingchapter:
SystemLevel AsdefinedintheQTRManufacturingSystems/UnitOperaHons
TechnologyandequipmentusedformanufacturingprocessandnonprocessunitoperaAons
ProducHon/FacilitySystems
Equipment,processflow,andenergystrategiesthatcompriseagoods-producingfacility
Supply-ChainSystems FaciliAesandoperaAonsinvolvedinmovingmaterialsthroughanindustry,fromtheextracAonofrawmaterialstotheproducAonoffinishedgoods.
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TechnologyopportuniHesexistateachsystemslevel
SystemLevel Examples R&DOpportunityExamplesManufacturingSystems/UnitOperaHons
• Composites/curingsystem• ChemicalsseparaYonsystem• Lowthermal-budgetprocess
heaYng
• TransiYonfromautoclavetoout-of-theautoclavetechnology
• TransiYonfromdisYllaYontomembranes
• Smartmanufacturingequipment
ProducHon/FacilitySystems
• Petroleumrefinery• Vehicleassemblyplant• Facilitysteamsystems• Enterprisecomputer/control
systems
• ProcessintensificaYon• Smartenterprisesystems• AdvancedCHPsystems• Grid-friendlyequipment
Supply-ChainSystems • Steelindustry• TransportaYonequipment
industry• Distributedmanufacturing
• Recyclability/designforre-use• AlternaYvematerials
development• Useoflow-carbonfuelsand
feedstocks• TechnologyopportuniYesto
transformmarkets
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AdvancedMaterialsManufacturing
ManufacturingSystems–UnitOperaHons
ProducHon/FacilitySystems–EnergyandResourceUHlizaHon
SustainableManufacturing/FlowofMaterialsthroughIndustry
CriHcalMaterials
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiHons
AddiHveManufacturing
CompositeMaterials
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
WasteHeatRecoverySystems
CombinedHeatandPowerSystems
BeyondthePlantBoundaries–SupplyChainandLifeCycle
Secondaryimpactsassessed
Manufacturingsystemslevelinchapter
Legend
23
QTRIndustry&ManufacturingTechnologyAssessments
TechnologyAssessmentsattheirprincipalmanufacturingsystemslevel:
SystemLevel QTRManufacturingTechnologyAssessmentsManufacturingSystems/UnitOperaHons
ExisAngProcesses;NewApproaches
• ProcessHeaAng• ProcessIntensificaAon• Roll-to-RollProcessing• AddiAveManufacturing
ProducHon/FacilitySystems
FuelFlexibilityandWasteEnergy;DataandAutomaAon
• CombinedHeatandPowerSystems• WasteHeatRecoverySystems• Adv.Sensors,Controls,PlaQormsandModelingforMfg.
Supply-ChainSystems
IncreasingSustainability;ManufacturingEnergy-EfficientProducts
• AdvancedMaterialsManufacturing• CriAcalMaterials• SustainableManufacturing• DirectThermalEnergyConv.Materials,Devices&Systems• MaterialsforHarshServiceCondiAons• WideBandgapSemiconductorsforPowerElectronics• CompositeMaterials
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Energy,CarbonandUseIntensityImprovements
25
EnergyIntensitye.g.:ProcessefficiencyProcessintegraYonWasteheatrecovery
CarbonIntensity,e.g.:Processefficiency
FeedstocksubsYtuYonGreenchemistry
Biomass-basedfuelsProcesschangesRenewables
UseIntensitye.g.:
RecyclingReuseandremanufacturingMaterialefficiencyand
subsYtuYonBy-products
Product-Service-Systems
��
Energy,CarbonandUseIntensityImprovements
26
EnergyIntensitye.g.:ProcessefficiencyProcessintegraYonWasteheatrecovery
CarbonIntensity,e.g.:Processefficiency
FeedstocksubsYtuYonGreenchemistry
Biomass-basedfuelsProcesschangesRenewables
UseIntensitye.g.:
RecyclingReuseandremanufacturingMaterialefficiencyand
subsYtuYonBy-products
Product-Service-Systems
��
Energy,CarbonandUseIntensityImprovements
27
��
AdvancedMaterialsManufacturing
ManufacturingSystems–UnitOperaHons
ProducHon/FacilitySystems–EnergyandResourceUHlizaHon
SustainableManufacturing/FlowofMaterialsthroughIndustry
CriHcalMaterials
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiHons
AddiHveManufacturing
CompositeMaterials
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
WasteHeatRecoverySystems
CombinedHeatandPowerSystems
BeyondthePlantBoundaries–SupplyChainandLifeCycle
Secondaryimpactsassessed
Manufacturingsystemslevelinchapter
Legend
TechnologyAssessments-Currenttechnologystatus,R&Dneeds,andpotenHalimpacts.
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SustainableManufacturing–FlowofMaterialsthroughIndustry
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiEons
AdvancedMaterialsManufacturing
AddiEveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaEon
ProcessHeaEng
WasteHeatRecoverySystems
CombinedHeatandPower
CriEcalMaterials
AdvancedSensors,Controls,PlaJormsandModelingfor
Manufacturing
Buildings TransportaEonGrid Fuels
ConnecEonstootherQTRChaptersandTechnologyAssessments
ElectricPower
SustainableManufacturingTechnologyAssessment–Scope:
• Supplychainissues,fromresourceextracYontoendoflife(LifeCycleAnalysis)• Flowdiagramstodemonstratesupplychainissues• Materialefficiency:mechanismsforreducingdemandformaterials(e.g.,lightweighYng,
scrapreducYon,increasedmateriallongevity)• DesignforRe-use/Recycling
SustainableManufacturing–FlowofMaterialsthroughIndustry
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiEons
AdvancedMaterialsManufacturing
AddiEveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaEon
ProcessHeaEng
WasteHeatRecoverySystems
CombinedHeatandPower
CriEcalMaterials
AdvancedSensors,Controls,PlaJormsandModelingfor
Manufacturing
Buildings TransportaEonGrid Fuels
ConnecEonstootherQTRChaptersandTechnologyAssessments
ElectricPower
Cross-EnergyConnecHons• ElectricPower:managementofwater&energyresources• Buildings:recyclingandmaterialssubsAtuAon/minimizaAon
SustainableManufacturingTechnologyAssessment-ConnecHons
Intra-ManufacturingConnecHons
• CriHcalMaterials:materialssubsAtuAon
• ProcessHeaHng:sharedownershipofequipmenttomaximizeproducAonintensity
• MaterialsforHarshServiceCondiHons/AdvancedMaterialsManufacturing:materialstoincreasedurabilityorfacilitatere-use
• CombinedHeatandPower/ProcessIntensificaHon:modularequipmentdesignforeasierreconfiguraAon,upgradeandrepair
• AddiHveManufacturing:distributedmanufacturing;rawmaterialminimizaAon
• CompositeMaterials:Lightweightmaterialsmanufacturingforlife-cycleenergysavings
• AdvancedSensors,Controls,PlaWorms,andModelingforManufacturing:smarttechnologiestoenabletrack&traceofmaterialsthroughthelifecycle
• WasteHeatRecovery:opAmizaAonofheatflowstomaximizeproducAonintensityandminimizewasteheatlosses
SustainableManufacturing–FlowofMaterialsthroughIndustry
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiEons
AdvancedMaterialsManufacturing
AddiEveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaEon
ProcessHeaEng
WasteHeatRecoverySystems
CombinedHeatandPower
CriEcalMaterials
AdvancedSensors,Controls,PlaJormsandModelingfor
Manufacturing
Buildings TransportaEonGrid Fuels
ConnecEonstootherQTRChaptersandTechnologyAssessments
ElectricPower
Cross-EnergyConnecHons• ElectricPower:managementofwater&energyresources• Buildings:recyclingandmaterialssubsAtuAon/minimizaAon
SustainableManufacturingTechnologyAssessment-ConnecHons
Intra-ManufacturingConnecHons
• CriHcalMaterials:materialssubsAtuAon
• ProcessHeaHng:sharedownershipofequipmenttomaximizeproducAonintensity
• MaterialsforHarshServiceCondiHons/AdvancedMaterialsManufacturing:materialstoincreasedurabilityorfacilitatere-use
• CombinedHeatandPower/ProcessIntensificaHon:modularequipmentdesignforeasierreconfiguraAon,upgradeandrepair
• AddiHveManufacturing:distributedmanufacturing;rawmaterialminimizaAon
• CompositeMaterials:Lightweightmaterialsmanufacturingforlife-cycleenergysavings
• AdvancedSensors,Controls,PlaWorms,andModelingforManufacturing:smarttechnologiestoenabletrack&traceofmaterialsthroughthelifecycle
• WasteHeatRecovery:opAmizaAonofheatflowstomaximizeproducAonintensityandminimizewasteheatlosses
SustainableManufacturing–FlowofMaterialsthroughIndustry
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiEons
AdvancedMaterialsManufacturing
AddiEveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaEon
ProcessHeaEng
WasteHeatRecoverySystems
CombinedHeatandPower
CriEcalMaterials
AdvancedSensors,Controls,PlaJormsandModelingfor
Manufacturing
Buildings TransportaEonGrid Fuels
ConnecEonstootherQTRChaptersandTechnologyAssessments
ElectricPower
Cross-EnergyConnecHons• ElectricPower:managementofwater&energyresources• Buildings:recyclingandmaterialssubsAtuAon/minimizaAon
SustainableManufacturingTechnologyAssessment-ConnecHons
TechnologyHighlights–UseIntensityImprovements
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1.09kg
• 65%weightreducHon• 81%reducHoninbuy-to-flyraHo• 66%energysavings• Mostsavingsoccurinusephase
0.38kg
CaseStudy:OpHmizedAircralBracket
Source:MFIandLIGHTEnUPAnalysisNote:1quad=1×109MMBtu
• LightweightcomponentsforthetransportaYonsector
• Advancedtoolingformanufacturing
• Customproductsandsmall-batchproducYon
• Accelerateddesigncyclesforrapidproductdevelopment
ApplicaHonsinMulHpleSectors
• FabricaYonoflargeproducts• Distributedmanufacturing• Time-qualityopYmizaYon• Materialsefficiency
R&DChallenges
Energy,cost,andenvironmentalimpacts(throughoutlifecycle)areapplicaYondependent.
AddiHveManufacturing
Life-CycleEnergySavingsforAddiHveManufacturedAircralBracket
TechnologyHighlights–UseIntensityImprovements
34
ImpactsfromAircralFleet-WideAdopHonofAddiHveManufacturing
• LightweightcomponentsforthetransportaYonsector
• Advancedtoolingformanufacturing
• Customproductsandsmall-batchproducYon
• Accelerateddesigncyclesforrapidproductdevelopment
ApplicaHonsinMulHpleSectors
• FabricaYonoflargeproducts• Distributedmanufacturing• Time-qualityopYmizaYon• Materialsefficiency
R&DChallenges
Energy,cost,andenvironmentalimpacts(throughoutlifecycle)areapplicaYondependent.
AddiHveManufacturing
ScenarioSlowAdopHonnewaircranonly
Mid-RangeAdopHonnewaircranandnewparts
RapidAdopHonnewaircran,newparts,andacceleratedreplacement
AnnualEnergySavingsforFleet-WideAdopHonofAddiHveManufacturedComponentsinAircral
EnergySavingsBreakdown:Over95%ofsavingsoccurinusephase
Source:R.Huang,etal.,“TheEnergyandEmissionsSavingPotenYalofAddiYveManufacturing:TheCaseofLightweightAircranComponents.”(AnalysisInProgress). Note:1quad=1,000TBtu
SlowAdopYon Mid-RangeAdopYon RapidAdopYon
• CarbonFiber(CF)iscurrently~5xmoreenergyintensivethansteel:• ImprovedCFis~½energyintensitythanPAN:• Significantlyimprovedmaterialsandmanufacturingenergyimprovesnetenergyfootprint
TechnologyAssessment–LifeCycleEnergySavingsfromLight-weighHngCarbonFiberReinforcedPlasHcsvs.Steel
Theimportanceofimprovingmaterialsandmanufacturingenergyuse
Theimportanceofusephaseenergysavings
ORNL/DOEanalysis–preliminaryresults
35
36
TheCircularEconomy
37
CircularEconomy–InDecember2015,theEuropeanCommission2030targetsforrecyclingmunicipalwaste(65%)andpackagingwaste(75%).
1. ProducHon1.1.Productdesign1.2.ProducYonprocesses
2.ConsumpHon3.Wastemanagement4.Fromwastetoresources:boosHngthemarketforsecondaryrawmaterialsandwaterreuse5.Priorityareas
5.1.PlasYcs5.2.Foodwaste5.3.CriYcalrawmaterials5.4.ConstrucYonanddemoliYon5.5.Biomassandbio-basedproducts
6.InnovaHon,investment,andotherhorizontalmeasures7.Monitoringprogresstowardsacirculareconomy
38
“TheEuropeanCommission’sclearandconsistentrecyclingdefiniAonsareveryencouraging.Theproposaltomovethepointofmeasurementofrecyclingtoa]erthesorAngphaseratherthanatthecollecAonphasewillensurethatMemberStatesreportonrealrecyclingresults.”“Aboutonemilliontonnesofaluminiumscrapwasexportedin2014,thisisaneconomicwastemakingEuropeevenmorereliantonimports.ThiscouldbeavoidedthroughgreaterinvestmentinEuropeancollecAonandsorAnginfrastructure.ExporAngscrapislikeexporAngtheenergyembeddedinthemetal.IfwerecycledthisquanAtyhereinEuropewewouldsavetheequivalentoftheannualenergyconsumpAonofcountriessuchasLatviaorLuxembourg.”hOp://www.euracYv.com/secYons/sustainable-dev/europe-should-conYnue-strive-ideal-circular-economy-320140
39
ConsideraHonsaswestartthisworkshop….
• Whatsustainablemanufacturingtechnologiesandsystemimprovements*couldyieldthegreatesteconomy-wideimpacts?
• HowcanwesustainablyleveragedomesYcenergyresources(e.g.,NG)?
• WhatYmelyinvestmentscouldpotenYallyenableU.S.leadershipandopenmarkets?
40
*forexample:• DevelopingandUsingAlternaYve/SustainableFeedstocks• ReducYonofWasteinManufacturingProcesses• End-of-LifeManagement• Materials,WaterandEnergyManagement• SustainableDesignandDecision-Making
Back-UpSlides
41
42
CriHcalMaterials
Cross-EnergyConnecHons• ElectricPower:permanentmagnetsforwind
turbines• Buildings:phosphorsforLEDlighAng• TransportaHon:dysprosiumandotherrare
earthsformotors;plaAnumforfuelcellcatalysts
Intra-ManufacturingConnecHons• SustainableManufacturing:materials
subsAtuAon• AdvancedSensors,Controls,PlaWorms,and
ModelingforManufacturing:modelstominimizecriAcalmaterialsuse
• AdvancedMaterialsManufacturing:computaAonaltechniquestodevelopcriAcalmaterialalternaAves
SustainableManufacturing–FlowofMaterialsthroughIndustry
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
CombinedHeatandPower
CriHcalMaterials
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
Scope• DynamicnatureofcriYcality• Permanentmagnetsforwindturbinesandelectricvehicles• PhosphorsforenergyefficientlighYng• SupplydiversityandglobalmaterialcriYcality
43
DirectThermalEnergyConversionMaterials,DevicesandSystems
Cross-EnergyConnecHons• ElectricPower:waterwithdrawalforpower
plantcooling;wasteheatrecoveryinpowerplants
• Buildings:thermoelectricheatpumpsforHVAC• TransportaHon:directthermalenergy
conversionforinternalcombusAonengines
Intra-ManufacturingConnecHons• MaterialsforHarshServiceCondiHons:thermal
conversionmaterialsanddevicesforhigh-temperatureorcorrosiveenvironments
• Roll-to-Roll:thermoelectricdevicefabricaAonviaroll-to-roll
• Wasteheatrecovery:novelenergyconversionmaterials,devicesandsystemsforwasteheattopower
• AddiHveManufacturing:addiAvemanufacturingofthermoelectricmodules
• AdvancedSensors,Controls,PlaWormsandModelingforManufacturing:thermalcontrolsystems;powerforwirelesssensornetworksWideBandgapSemiconductors
forPowerElectronics
MaterialsforHarshServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
CombinedHeatandPower
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
DirectThermalEnergyConversionMaterials,DevicesandSystems
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
CriHcalMaterials
SustainableManufacturing–FlowofMaterialsthroughIndustry
Scope• Thermoelectricmaterials(includingnewprovenmaterialssuchasSkuOeruditesandHalf-Heusleralloys)• Newmanufacturingprocessessuchaswafer-basemanufacturingtoreplacepick-and-place• Wasteheatrecoveryequipment• ThermoelectricgeneraYonofelectricity(costtarget:$1/WaO)
44
WideBandgapSemiconductorsforPowerElectronics
Cross-EnergyConnecHons• Grid:solidstatetransformersforpowerflow
control;invertersforrenewableenergy• Buildings:variablespeeddrivesforHVAC
systems;AC-to-DCandDC-to-ACadapters• TransportaHon:Powerelectronicsforelectric
vehicles
Intra-ManufacturingConnecHons• SustainableManufacturing:smaller-footprint
electronicswithreducedcoolingrequirements• AdvancedSensors,Controls,PlaWormsand
ModelingforManufacturing:variablefrequencydrivesandmotorspeedcontrol
• AdvancedMaterialsManufacturing:low-cost,commercial-scaleproducAonmethodsforwidebandgapdevices
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
CombinedHeatandPower
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
DirectThermalEnergyConversionMaterials,DevicesandSystems
CriHcalMaterials
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
SustainableManufacturing–FlowofMaterialsthroughIndustry
Scope• OpportuniYesforsiliconcarbide(SiC)andgalliumnitride(GaN)toreplacesilicon(Si)inpowerelectronics• ApplicaYonsincludeACadapters,datacenters,andinvertersforrenewableenergygeneraYon
45
MaterialsforHarshServiceCondiHons
Cross-EnergyConnecHons• Fuels:corrosioninoffshoredrillingequipment;
ashfoulinginbiomassconversionequipment;hydrogenembrielementinH2pipelines
• ElectricPower:radiaAon-resistantfuelcladding;high-temperaturealloysfornuclearreactorsandgasandsteamturbines
• TransportaHon:corrosion-resistantlightweightmaterials
Intra-ManufacturingConnecHons• SustainableManufacturing/Advanced
MaterialsManufacturing:materialstoincreasedurabilityorfacilitatere-use;materialsgenometechniquesfornewmaterialsdevelopment
• CompositeMaterials:lightweight,durablestructuralcomponentsforautomobiles;erosion-resistantcompositesforwindturbinebladesandturbomachinery
• DirectThermalEnergyConversion:thermalconversionmaterialsanddevicesforhigh-temperatureorcorrosiveenvironments
• AdvancedSensors,Controls,PlaWormsandModelingforManufacturing:computaAonalmodelingtosupportadvancedmaterialsdevelopment;MaterialsforHarsh
ServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
CombinedHeatandPower
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
CriHcalMaterials
SustainableManufacturing–FlowofMaterialsthroughIndustry
Scope• Materialsforextremeenvironmentsincludinghightemperatures,highpressures,corrosivechemicals,heavy
mechanicalwear,nuclearradiaYon,andhydrogenexposure
46
AdvancedMaterialsManufacturing
Cross-EnergyConnecHons• ElectricPower:Materialsgenometechniquesto
screenmaterialsforuseincarboncaptureandstorage(CCS)applicaAons
• Buildings:Advancedbuildingenvelopematerials• TransportaHon:PredicAvedesign,modeling,and
simulaAonforvehicleproductdevelopment
Intra-ManufacturingConnecHons• AddiHveManufacturing:materialformulaAons
foraddiAvetechniques• Roll-to-Roll:thin-andthick-filmsubstrate
producAon;mulAlayeralignment• SustainableManufacturing/Materialsfor
HarshServiceCondiHons:materialstoincreasedurabilityorfacilitatere-use;materialsgenometechniquesfornewmaterialsdevelopment
• AdvancedSensors,Controls,PlaWormsandModelingforManufacturing:computaAonalmodelingtosupportadvancedmaterialsdevelopment;controlsandsensorstosupportadvancedmanufacturingtechniques
• WideBandgapSemiconductors:low-cost,commercial-scaleproducAonmethodsforwidebandgapdevices
MaterialsforHarshServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
CombinedHeatandPower
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
CriHcalMaterials
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
SustainableManufacturing–FlowofMaterialsthroughIndustry
Scope• Broad-brushdiscussionofnextgeneraYonmaterials,technicalbarriers,andopportuniYes• EmergingprocessesforadvancedmaterialsproducYon• MaterialsGenomeandcomputaYonalmanufacturingasrelatedtoCleanEnergyManufacturing
47
AddiHveManufacturing
Cross-EnergyConnecHons• Fuels:fuelcells• ElectricPower:customelectricalcomponentsin
substaAons;complexpartsforpowerplants;toolingforlargecasAngsforpowerplants
• Buildings:heatexchangersforHVACsystems;windowframes
• TransportaHon:PrototypingandtoolinginautomoAveapplicaAons;fuelcells
Intra-ManufacturingConnecHons• AdvancedSensors,Controls,PlaWormsand
ModelingforManufacturing:metrologyandcontrolsystemsforimprovedquality,defectdetecAon,andthroughput
• ProcessIntensificaHon:microchannelreactorfabricaAon
• Roll-to-RollManufacturing:commontechnologyneedsforaddiAve2-D(roll-to-roll)and3-D(addiAvemanufacturing)prinAngtechnologies
• CompositeMaterials:3-DprinAngofreinforcedpolymersandothercomposites
• AdvancedMaterialsManufacturing:materialformulaAonsforaddiAvetechniques
• DirectThermalEnergyConversion:addiAvemanufacturingofthermoelectricmodulesMaterialsforHarsh
ServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
CombinedHeatandPower
CriHcalMaterials
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
SustainableManufacturing–FlowofMaterialsthroughIndustry
Scope• StructuralcompositematerialsforlightweighYng,includingautomoYve,wind,andgasstorageapplicaYons• Formingandcuringtechnologiesforthermose{ngandthermoplasYcpolymercomposites
48
CompositeMaterials
Cross-EnergyConnecHons• Fuels:hydrogenfuelstorage• ElectricPower:lightweightwindturbineblades• TransportaHon:compressedgasstoragefor
mobileapplicaAons;automoAvelightweighAng
Intra-ManufacturingConnecHons• AddiHveManufacturing:3-DprinAngof
reinforcedpolymersandothercomposites• MaterialsforHarshServiceCondiHons:
lightweight,durablestructuralcomponentsforautomobiles;erosion-resistantcompositesforwindturbinebladesandturbomachinery
• AdvancedSensors,Controls,PlaWormsandModelingforManufacturing:inspecAontechniquesforqualitycontrol;automatedtapelayingandautomatedtapeplacement
• SustainableManufacturing:Lightweightmaterialsmanufacturingforlife-cycleenergysavings
MaterialsforHarshServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
CombinedHeatandPower
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
CriHcalMaterials
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
SustainableManufacturing–FlowofMaterialsthroughIndustry
Scope• StructuralcompositematerialsforlightweighYng,includingautomoYve,wind,andgasstorageapplicaYons• Formingandcuringtechnologiesforthermose{ngandthermoplasYcpolymercomposites
49
Roll-to-RollProcessing
Cross-EnergyConnecHons• ElectricPower:flexiblesolarpanels• Buildings:windowinsulaAonfilms• TransportaHon:baeeryelectrodes
Intra-ManufacturingConnecHons• AdvancedSensors,Controls,PlaWormsand
ModelingforManufacturing:metrologyandcontrolsystemsforimprovedquality,defectdetecAon,andthroughput
• ProcessIntensificaHon:roll-to-rollforproducAonofseparaAonmembranes
• AddiHveManufacturing:commontechnologyneedsforaddiAve2-D(roll-to-roll)and3-D(addiAvemanufacturing)prinAngtechnologies
• DirectThermalEnergyConversion:thermoelectricdevicefabricaAonviaroll-to-roll
• AdvancedMaterialsManufacturing:thin-andthick-filmsubstrateproducAon;mulAlayeralignment
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
CombinedHeatandPower
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
DirectThermalEnergyConversionMaterials,DevicesandSystems
CriHcalMaterials
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
SustainableManufacturing–FlowofMaterialsthroughIndustry
Scope• Roll-to-roll(R2R)applicaYonssuchasflexiblesolarpanels,printedelectronics,thinfilmbaOeries,andmembranes• DeposiYonprocessessuchasevaporaYon,spuOering,chemicalvapordeposiYon,andatomiclayerdeposiYon• MetrologyforinspecYonandqualitycontrol
50
ProcessIntensificaHon
Cross-EnergyConnecHons• Fuels:naturalgasandmodularproducAon• ElectricPower:chemicalconversionof
biofeedstocks;separaAonsforCCS• Buildings:membranesfordehumidificaAon• TransportaHon:adsorbentsystemsfor
compressedgasstorage
Intra-ManufacturingConnecHons• ProcessHeaHng/WasteHeatRecovery:
integratedcontrolsystems;replacementofbatchoperaAonswithconAnuousones;facilityintegraAontoenablere-useofexhaustgasesinlower-temperatureprocesses
• CombinedHeatandPower/SustainableManufacturing:modularequipmentdesignforeasierreconfiguraAon,upgradeandrepair
• Roll-to-RollProcessing:roll-to-rollforproducAonofseparaAonmembranes
• AddiHveManufacturing:microchannelreactorfabricaAon
• AdvancedSensors,Controls,PlaWorms,andModelingforManufacturing:on-linedataacquisiAonandmodelingforprocesscontrol;enterprise-wideoperaAonsopAmizaAon
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
SustainableManufacturing–FlowofMaterialsthroughIndustry
CriHcalMaterials
CombinedHeatandPower
DirectThermalEnergyConversionMaterials,DevicesandSystems
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
Scope• ProcessintensificaYonequipmentandmethods• SeparaYonstechnologies• Feedstockuseandfeedstockconversiontechnologies• Focusontheenergy-intensivechemicalsector
51
ProcessHeaHngSystems
Cross-EnergyConnecHonsNone,asthisisamanufacturing-specifictechnology
Intra-ManufacturingConnecHons• CHP:integraAonofCHPwithprocessheaAng
equipment• SustainableManufacturing:sharedownership
ofequipmenttomaximizeproducAonintensity• WasteHeatRecovery:wasteheatrecoveryfrom
processheaAngequipment;facilityintegraAontoenablere-useofexhaustgasesinlower-temperatureprocesses
• ProcessIntensificaHon:integratedcontrolsystems;replacementofbatchoperaAonswithconAnuousonesSustainableManufacturing–
FlowofMaterialsthroughIndustryDirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
CombinedHeatandPower
CriHcalMaterials
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
Scope• Lowthermalbudgettechnologies• SensorsandprocesscontrolsforprocessheaYngequipment• ProcessheaYngenergysavingopportuniYes,e.g.wasteheatrecovery,non-thermaldrying,andlow-energyprocessing• Fuel,electricity,steam,andhybridsystems
52
AdvancedSensors,Controls,PlaWorms,andModelingforManufacturing
Cross-EnergyConnecHons• Grid:advancedmetering;sensorsforpowerflow• ElectricPower:gridintegraAon• Buildings:advancedsensorsforlighAngand
HVAC• TransportaHon:vehiclesenginecontrolsystems
Intra-ManufacturingConnecHonsConnecHonsspanningallmanufacturingtechnologies,including:integratedsensorsandcontrolsforincreasedmanufacturingthroughput,efficiency,andqualitycontrol;computaAonalmodelsforsimulaAonsandacceleratedmaterialsdevelopment
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
CriHcalMaterials DirectThermalEnergyConversion
Materials,DevicesandSystems
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
WasteHeatRecoverySystems
CombinedHeatandPower
SustainableManufacturing–FlowofMaterialsthroughIndustry
Scope• Smartsystemsandadvancedcontrols• Advancedsensorsandmetrology,includingpower/costsensorsandcomponenttrackingacrossthesupplychain• Distributedmanufacturing• PredicYvemaintenance• ProductcustomizaYon• HPC,cloudcompuYngandopYmizaYonalgorithms
WasteHeatRecoverySystems
Cross-EnergyConnecHons• ElectricPower:wasteheatrecovery
opportuniAesinelectricgeneraAon• Buildings:heatexchangersinHVACsystems• TransportaHon:wasteheatrecoveryfrom
internalcombusAonengines
Intra-ManufacturingConnecHons• CHP:heatrecoveryinCHPsystems• SustainableManufacturing:opAmizaAonof
heatflowstomaximizeproducAonintensityandminimizewasteheatlosses
• DirectThermalEnergyConversion:novelenergyconversionmaterials,devicesandsystemsforwasteheattopower
• AdvancedSensors,Controls,PlaWormsandModelingforManufacturing:sensorstomonitortemperature,humidity,andlowerexplosionlimitstoenableincreasedexhaustgasrecycling;predicAvemodelsforcombusAon
• ProcessIntensificaHon:integratedcontrolsystems;replacementofbatchoperaAonswithconAnuousones
• ProcessHeaHng:wasteheatrecoveryfromprocessheaAngequipment;facilityintegraAontoenablere-useofexhaustgasesinlower-temperatureprocesses
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
CombinedHeatandPower
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
CriHcalMaterials
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
SustainableManufacturing–FlowofMaterialsthroughIndustry
Scope• Wasteheatrecoverytechnologies,includingrecuperators,recuperaYveburners,staYonaryandrotaryregenerators,
andshell-and-tubeheatexchangers• Majorwasteheatsourcessuchasblastfurnaces,electricarcfurnaces,melYngfurnaces,andkilns• OpportuniYesforlow,medium,andhigh-temperaturewasteheatrecovery
53
54
CombinedHeatandPowerSystems
Cross-EnergyConnecHons• Grid:CHPfordistributedgeneraAon• ElectricPower:CHPfordistributedgeneraAon
Intra-ManufacturingConnecHons• SustainableManufacturing/Process
IntensificaHon:modulardesignforeasierreconfiguraAon,upgradeandrepair
• WasteHeatRecovery:heatrecoveryinCHPsystems
• AdvancedSensors,Controls,PlaWorms,andModelingforManufacturing:modelstosupportdevelopmentofhigh-efficiencyCHPconfiguraAons;improvedcontrolsforgridintegraAon
• ProcessHeaHng:integraAonofCHPwithmanufacturingequipment
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
CombinedHeatandPower
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
CriHcalMaterials
TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower Buildings
SustainableManufacturing–FlowofMaterialsthroughIndustry
Scope• Supplychainissues,fromresourceextracYontoendoflife(LifeCycleAnalysis)• FlowdiagramstodemonstratesupplychainissuesMaterialefficiency:mechanismsforreducingdemandformaterials
(e.g.,lightweighYng,scrapreducYon,increasedmateriallongevity)• DesignforRe-use/Recycling
55
SustainableManufacturing/FlowofMaterialsthroughIndustry
Cross-EnergyConnecHons• ElectricPower:managementofwater&energy
resources• Buildings:recyclingandmaterialssubsAtuAon/
minimizaAon
Intra-ManufacturingConnecHons• CriHcalMaterials:materialssubsAtuAon• ProcessHeaHng:sharedownershipof
equipmenttomaximizeproducAonintensity• MaterialsforHarshServiceCondiHons/
AdvancedMaterialsManufacturing:materialstoincreasedurabilityorfacilitatere-use
• CombinedHeatandPower/ProcessIntensificaHon:modularequipmentdesignforeasierreconfiguraAon,upgradeandrepair
• AddiHveManufacturing:distributedmanufacturing;rawmaterialminimizaAon
• CompositeMaterials:Lightweightmaterialsmanufacturingforlife-cycleenergysavings
• AdvancedSensors,Controls,PlaWorms,andModelingforManufacturing:smarttechnologiestoenabletrack&traceofmaterialsthroughthelifecycle
• WasteHeatRecovery:opAmizaAonofheatflowstomaximizeproducAonintensityandminimizewasteheatlosses
SustainableManufacturing–FlowofMaterialsthroughIndustry
DirectThermalEnergyConversionMaterials,DevicesandSystems
WideBandgapSemiconductorsforPowerElectronics
MaterialsforHarshServiceCondiHons
AdvancedMaterialsManufacturing
AddiHveManufacturing
CompositeMaterialsManufacturing
Roll-to-RollProcessing
ProcessIntensificaHon
ProcessHeaHng
WasteHeatRecoverySystems
CombinedHeatandPower
CriHcalMaterials
AdvancedSensors,Controls,PlaWormsandModelingfor
Manufacturing
Buildings TransportaHonGrid Fuels
ConnecHonstootherQTRChaptersandTechnologyAssessments
ElectricPower
Scope• Supplychainissues,fromresourceextracYontoendoflife(LifeCycleAnalysis)• FlowdiagramstodemonstratesupplychainissuesMaterialefficiency:mechanismsforreducingdemandformaterials
(e.g.,lightweighYng,scrapreducYon,increasedmateriallongevity)• DesignforRe-use/Recycling
IntroducHon-FlowofEnergythroughtheU.S.Economy
56
IntroducHon–FlowofEnergyThroughManufacturing
Note:1quad=1,000TBtu57
Driver–EnergyIntensityImprovementsTechnicalEnergySavingsOpportuniHes:Iron&SteelIndustry2015BandwidthStudy–potenHalbymajorprocessarea
Source:DOE/AMO,Iron&SteelIndustryEnergyBandwidthStudy(2014) Note:1quad=1000TBtu58
FinalProcessing
SecondaryProcessing(8.72kg)
KeyassumpHons:• Ingotembodied(source)energy918MJ/kg(255kWh/kg)[5]• Forging1.446kWh/kg[5],AtomizaYon1.343kWh/kg[6,7,8],Machining9.9kWh/kgremoved[9],SLM29kWh/kg[10,11],EBM17kWh/kg[10]• 11MJprimaryenergyperkWhelectricity• Machiningpathwaybuy-to-fly33:1[15],supplychainbuypoint=forgedproduct(billet,slab,etc.)• AMpathwaybuy-to-fly1.5:1,supplychainbuypoint=atomizedpowder• ArgonusedinatomizaYonandSLMincludedinrecipesbutnotfactoredintoenergysavingsinthispresentaYon
Powder ElectronBeamMelYng(EBM)
Addi3veManufacturing-Buy-to-FlyRa3o1.5:1
FinishedPart
Source:MFIandLIGHTEnUPAnalysis
PrimaryProcessing(15.9MJ/kg)
FinishedPartMillProduct(slab,billet,
etc.)
MachinedProduct
Conven3onalMachining-Buy-to-FlyRa3o8:1
AtomizaHon(14.8MJ/kg)
(0.57kg)
FinalProcessing(0.38kg)
1.09kg
0.38kg
*“Average”convenYonalbracket1.09kg,“average”AMbracket0.38kg
Ingot(918MJ/kgembodiedenergy)
TechnologyAssessment–AddiHveManufacturingExample:OpHmizedAircralBracket
59
Driver–CarbonIntensity
60
Directemissionswithefficiencyimprovements,…
…andwithfuelswitchingandmaterialsubsYtuYon
ExampleanalysisusingtheBuildings,Industry,Transport,ElectricityScenario(BITES)tool
CarboncaptureandsequestraYon(CCS)technologiesofferaddiYonalopportuniYes
Agriculture,mining,construcYon:OpportuniYesforadvancedengines,biofuels,etc.
60
Driver–UseIntensity:AluminumExample
MaterialsShin–ToenableincreaseofsecondaryaluminumEnd-of-lifeshin–Toenablegreatercaptureanduseoflandfill+scrapexportSystems-wide–Materials&productdesign,manufacturing,useandre-use.
61